JP5127975B1 - ハニカムパネル積層体の製造方法及びハニカムパネル積層体 - Google Patents
ハニカムパネル積層体の製造方法及びハニカムパネル積層体 Download PDFInfo
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Abstract
【解決手段】吸音面、吸音層、反射面からなる積層体において、吸音面は発泡体4よりなり、吸音層はハニカム材と空間部に硬質フォーム材3を充填させた層から成り、吸音層のハニカム材の先端部に接着剤2を塗布し、該先端部を上記吸音面に対して押し当て、該発泡体に食い込ませて接着させた構造を有し、さらにハニカム材の反対側の面となる遮音面は、発泡体6からなり、上記ハニカム材と接する面に接着剤5を一面に塗布し、該ハニカム材セル隔壁1の逆の先端部を上記遮音面に対して押し当て、接着剤を一面に塗布した該発泡体に食い込ませた接着構造を有するハニカムパネル積層体。
【選択図】図4
Description
このように、得られる接着力が小さいために、場合によっては、ハニカム材と面材の間に間隙を生じ、遮音効果を減じ、騒音対策の構造材としては、不適切となり、またハニカムパネル積層体としての全体の強度不足を招来し、建材として、適用範囲が限定されるという問題があった。
これを実現する為に、図4−1のように遮音面6を構成する独立気泡ポリエチレンフォーム材の両面に接着剤5を塗布(図5で遮音面6の両面に破線で示されている)しておき、ハニカム材セル隔壁1と接触する面と反対側の接着剤面の外側には、剥離し易い保護紙17をさらに貼り付けておく。
そこで、図7でセル隔壁12に垂直な面14の面内でハニカムパネル積層体全体を彎曲させよう(例えば15の矢印の方向、紙面にたいして上下方向に曲げる)と、徐々に応力を加えて行くと、比較的初期段階に、セル隔壁12以外のセル隔壁がひねり応力によりひねり変形する。その段階ではセル隔壁12はひねり変形することはないが、この方向に彎曲するには、セル隔壁12がひねり変形する必要がないので、ハニカムパネル積層体全体として彎曲させることが出来る。これに対し、面14とは異なる面内で彎曲させようとすると程度の差はあるが、セル隔壁12がどうしてもひねり変形することが必要になるが、セル隔壁12は、2重構造でしかも接着剤で強固に固められているので、ひねり応力に対する耐力が大きく、容易にひねり変形をしない。したがって、ハニカムパネル積層体を全体として、容易に彎曲させることが出来ない。
345×320×300H mm角での6面が吸遮音構造のBOXにより、減音性能を測定した結果を表1に示す。測定において、騒音の音源基準はセイコウ目覚まし時計スーパー雷電(直近MAX値100dBA))を使用し、音源はBOXの中心、音源と測定機器(リオンNA−27)の距離は500mmを測定基準とした。尚アルミ板付構造のハニカムパネル積層体の場合のアルミ板厚は、比較基準BOXのアルミ板1.2mm厚に合わせた。
表1 単位:dBA
表1において、本発明(ケース1)は、図4の構造を有するハニカムパネル積層体で、積層体の厚さは38.0mmで、内訳は、連通気泡ポリエチレンフォーム厚3mm、接着剤、ハニカム材及び充填フェノールフォーム厚30mm、接着剤、独立気泡ポリエチレンフォーム厚5mmである。
基準音源は、ハニカムパネル積層体の代わりに、アルミ板厚1.2mmで囲った反射BOXである。
又本発明(ケース1)を本発明(ケース2)と比較すると、全体厚さが16.2mmと薄いに係らず、3150Hz以上では、本発明(ケース2)の方が、本発明(ケース1)より減音効果が大きいことが分かった。。
ハニカム材は、ハニカム6角形を形成する6面の内、図7に示したセル隔壁12の2面が2重の接着層で強化されており、接着層であるセル隔離壁12と垂直をなす平面14の中では曲げ易く、セル隔壁12と平行な面内では曲げ難い。
図5−1及び図6−2を事前に目的物のRに合わせ、図4−1構造に予め曲げ癖をつけておくと取り付けし易い。矢印13の円弧方向に伸縮し、曲面体への取付けが容易になる。
2: ハニカム材セル隔壁の先端部に塗布された酢酸ビニール系樹脂接着剤3:セル充填材の連通気泡硬質フェノールフォーム材
4:吸音面の柔軟な連通気泡ポリエチレンフォーム材
5:遮音材独立気泡ポリエチレンフォーム材の接着に使用する接着剤
6:遮音材の柔軟な独立気泡ポリエチレンフォーム材
7:平板の剛体材
8:事前に曲げられた剛体材
9:現場の既設遮音構造体の平板及び曲面体(金属、コンクリート製等)
10:遮音材である平らな剛体材
11:ハニカム材がポリエチレンフォーム材に食い込んだ部分
12:ハニカム材の形状を維持する接着部分
13:円弧方向へ曲る方向を示した矢印
14:隔壁に垂直な平面
15:曲げる方向を示した矢印
16:6角形ハニカム材要素図
17:接着剤用の保護紙
Claims (4)
- 吸音面、吸音層、遮音面からなる積層体において、
吸音面はスポンジ系発泡体よりなり、
吸音層はハニカム材と該ハニカム材のセルの空間部に硬質フォーム材を充填させた層から成り、
該吸音層を構成する該ハニカム材のセル空間部に硬質フォーム材を充填する前に、該ハニカム材のセル隔壁の六角形線条先端部並びにセル隔壁立ち上がりの壁面に接着剤を塗布し、該セル隔壁の六角形線条先端部をスポンジ系発泡体よりなる上記吸音面に対して突き合せ、接着剤を塗布した該セル隔壁の六角形線条先端部を該スポンジ系発泡体にさらに圧力を加えて押しつけ、食い込ませて接着させ、
しかる後に、該ハニカム材のセル空間部に該ハニカム材の厚さと略同一厚さの硬質フォーム材を該硬質フォーム材の気泡が潰れない程度の圧力をかけながら上記ハニカム材の他の一面から押し込み、該ハニカム材のセル隔壁と該硬質フォーム材の高さが大略同一に揃った面状態となるように、充填させて、吸音層を構成し、
さらに上記吸音面とは平行でかつ該ハニカム材の反対側の面となる遮音面は、スポンジ系発泡体からなり、
該遮音面の上記ハニカム材と接することになる面に接着剤を一面に塗布し、該ハニカム材のセル隔壁と該硬質フォーム材の高さが大略同一に揃った面状態のままの該吸音層の該ハニカム材のセル隔壁の接着剤を塗布した先端部と逆側の先端部をスポンジ系発泡体から成る上記遮音面の接着剤を塗布した面に対して突き合せ、該逆側の先端部を接着剤を一面に塗布した該スポンジ系発泡体にさらに圧力を加えて押しつけ、食い込ませて接着させる
ことを特徴とするハニカムパネル積層体の製造方法。
- 請求項1に記載の製造方法で製造される積層体であって、
吸音面を構成するスポンジ系発泡体が連通気泡であり、
吸音層の硬質フォーム材が連通気泡であり、
遮音面を構成するスポンジ系発泡体が独立気泡である
ことを特徴とするハニカムパネル積層体。
- 吸音面及び遮音面に使用するスポンジ系発泡体はポリエチレンフォーム材からなる請求項2に記載のハニカムパネル積層体。
- 充填フォーム材は硬質フェノールフォーム材からなる請求項2に記載のハニカムパネル積層体。
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